Analysis of an Emulsification Process Using Fractional Experimental Design

ABSTRACT

Soy oil-in-water emulsions (30% oil) with soy lecithin as emulsifier (4%) were prepared using a stirred vessel under batch conditions. The effects of 7 process variables (impeller-to-tank diameter ratio, temperature, agitation speed, mode of cooling and also pre-emulsification mixing rate, pre-emulsification mixing time and resting time before emulsification) were studied according to a fractional factorial design 2^7?3. The droplet size distributions of the emulsions were measured and the kinetics of destabilization were monitored during 3 months. In the experimental domain, the mixing rate was found to be the most significant variable affecting both the size distribution and the stability. It was followed by the temperature, and the impeller-to-tank ratio depending on the Sauter mean diameter or the half-life time of the emulsions. Interaction of the temperature with the agitation speed and with the impeller-to-tank diameter ratio was also observed.     

Influence of interfacial characteristics on Ostwald ripening in hydrocarbon oil-in-water emulsions

The influence of the nature of the interfacial membrane on the kinetics of droplet growth in hydrocarbon oil-in-water emulsions was investigated. Droplet growth rates were determined by measuring changes in the droplet size distribution of 1 wt % n-tetradecane or n-octadecane oil-in-water emulsions using laser diffraction. The interfacial properties of the droplets were manipulated by coating them with either an SDS layer or with an SDS-chitosan layer using an electrostatic deposition method. The emulsion containing SDS-coated octadecane droplets did not exhibit droplet growth during storage for 400 h, which showed that it was stable to Ostwald ripening because of this oils extremely low water-solubility. The emulsion containing SDS-coated n-tetradecane droplets showed a considerable increase in mean droplet size with time, which was attributed to Ostwald ripening associated with this oils appreciable water-solubility. On the other hand, an emulsion containing SDS-chitosan coated n-tetradecane droplets was stable to droplet growth, which was attributed to the ability of the interfacial membrane to resist deformation because of its elastic modulus and thickness. This study shows that the stability of emulsion droplets to Ostwald ripening can be improved by using an electrostatic deposition method to form thick elastic membranes around the droplets.     

Effects of heat on physicochemical properties of whey protein-stabilised emulsions

The effect of heating has been studied for whey protein-stabilised oil-in-water emulsions (25.0% (w/w) soybean oil, 3.0% (w/w) whey protein isolate, pH 7.0). These emulsions were heated between 55 and 95 °C as a function of time and the effect on particle size distribution, adsorbed protein amount, protein conformation and rheological properties was determined. Heating the emulsions as a function of temperature for 25 min resulted in an increase of the mean diameter (d₃₂) and shear viscosity with a maximum at 75 °C. Heating of the emulsions at different temperatures as a function of time in all cases resulted in a curve with a maximum for d₃₂. A maximum increase of d₃₂ was observed after about 45 min at 75 °C and after 6–8 min at 90 °C. Similar trends were observed with viscosity measurements. Confocal scanning laser micrographs showed that after 8 min of heating at 90 °C large, loose aggregates of oil droplets were formed, while after 20 min of heating compact aggregates of two or three emulsion droplets remained. An increase of the adsorbed amount of protein was found with increasing heating temperature. Plateau values were reached after 10 min of heating at 75 °C and after 5 min of heating at 90 °C. Based on these results we concluded that in the whole process of aggregation of whey protein-stabilised emulsions an essential role is played by the non-adsorbed protein fraction, that the kinetics of the aggregation of whey protein-stabilised emulsions follow similar trends as those for heated whey protein solutions and that upon prolonged heating rearrangements take place leading to deaggregation of initially formed large, loose aggregates of emulsion droplets into smaller, more compact ones.     

Experimental Investigation of Rheological and Morphological Properties of Water in Crude Oil Emulsions Stabilized by a Lipophilic Surfactant

Rheological behavior of two crude oils and their surfactant-stabilized emulsions with initial droplet sizes ranging from 0.5 to 75 µm were investigated at various temperatures under steady and dynamic shear testing conditions. In order to evaluate the morphology and Stability of emulsions, microscopic analysis was carried out over three months and average diameter and size distribution of dispersed droplets were determined. The water content and surfactant concentration ranged from 10 to 60% vol/vol and 0.1 to 10% wt/vol, respectively. The results indicated that the rheological properties and the physical structure and stability of emulsions were significantly influenced by the water content and surfactant concentration. The crude oils behaved as Newtonian fluids over a wide range of shear rates, whereas the emulsions behaved as non-Newtonian fluids, indicating shear-thinning effects over the entire range of shear rates. The viscosity, storage modulus and degree of elasticity were found to be significantly increased with the increase in water content and surfactant concentration. The maximum viscosity was observed at the point close to the phase inversion point where the emulsion system changes from water-in-oil emulsion to oil-in-water emulsion. The results also indicated that the rheological properties of crude oils and their emulsions are significantly temperature-dependent.     

Effect of molecular weight and degree of deacetylation of chitosan on the formation of oil-in-water emulsions stabilized by surfactant-chitosan membranes

The objective of this study was to establish the influence of polyelectrolyte characteristics (molecular weight and charge density) on the properties of oil-in-water emulsions containing oil droplets surrounded by surfactant-polyelectrolyte layers. A surfactant-stabilized emulsion containing small droplets (d32 approximately 0.3 microm) was prepared by homogenizing 20 wt% corn oil with 80 wt% emulsifier solution (20 mM SDS or 2.5 wt% Tween 20, 100 mM acetate buffer, pH 3) using a high-pressure valve homogenizer. This primary emulsion was then diluted with various chitosan solutions to produce secondary emulsions with a range of chitosan concentrations (3 wt% corn oil, 0-1 wt% chitosan). The influence of the molecular characteristics of chitosan on the properties of these emulsions was examined by using chitosan ingredients with different molecular weights (MW approximately 15, 145, and 200 kDa) and degree of deacetylation (DDA approximately 40, 77, and 92%). The electrical charge and particle size of the secondary emulsions were then measured. Extensive droplet aggregation occurred when the chitosan concentration was below the amount required to saturate the droplet surfaces, but stable emulsions could be formed at higher chitosan concentrations. The zeta-potential and mean diameter (d32) of the particles in the secondary emulsions was not strongly influenced by chitosan MW, however the chitosan with the lowest DDA (40%) produced droplets with smaller mean diameters and zeta-potentials than the other two DDA samples examined. Interestingly, we found that stable multilayer emulsions could be formed by mixing medium or high MW chitosan with an emulsion stabilized by a non-ionic surfactant (Tween 20) due to the fact the initial droplets had some negative charge. The information obtained from this study is useful for preparing emulsions stabilized by multilayer interfacial layers.     

An Electrorheological Study on the Behavior of Water‐in‐Crude Oil Emulsions Under Influence of a DC Electric Field and Different Flow Conditions

The influence of an applied DC electric field on viscosity and droplet size distribution of different water‐in‐crude oil emulsions was monitored in order to investigate the induction of coalescence of the water droplets. The effects caused by the voltage imposition were studied by rheological analysis and the validity of the obtained results was discussed, comparing with the features of real electrocoalcscer systems. A low field NMR technique (CPMG NMR) and digital video microscopy (DVM) were used to elucidate the behavior of the emulsions. Experiments performed at low shear rate with increasing electric field magnitude showed an increase in viscosity until a critical value. E_CRIT was reached. Thereafter coalescence occurred and viscosity decreased irreversibly below its initial value. The electrorheological behavior of the emulsions can be attributed to the organization (flocculation) of water droplets induced by the electric field, accompanied by an increase in viscosity. The structure breaks down as the shear rate is increased, leading to a decrease in viscosity. Experiments performed at high shear showed only a small decline in the viscosity. Although it was evident that coalescence took place, it did not involve the whole sample, because the electrodes were uncoated. As a direct consequence, the mean value of the droplet size within the emulsion did not change noticeably. Nonetheless this mean value was less recurrent and the formation of droplets of very large diameter occurred.     

Theoretical prediction of emulsion color

The perceived quality of many commercial products that are based on emulsions is determined by their color. In this article, a theory is presented to relate the color of emulsions to their composition and microstructure. First, the scattering characteristics (Qs and g) of individual droplets are calculated using Mie Theory. Second, the scattering (S) and absorption (K) coefficients of a concentrated emulsion are calculated using radiative transfer theory. Third, the reflectance spectrum (R) of the emulsion is calculated using Kubelka-Munk Theory. Finally, the tristimulus coordinates (XYZ, or L*a*b*) of the emulsion are calculated using color theory. There is excellent agreement between theoretical predictions and experimental measurements of the influence of droplet and chromophore characteristics on the tristimulus coordinates of concentrated oil-in-water emulsions.     

Structures and stability of lipid emulsions formulated with sodium caseinate

The physicochemical properties of emulsions play an important role in food systems as they directly contribute to texture, sensory and nutritional properties of foods. Sodium caseinate (NaCas) is a well-used ingredient because of its good solubility and emulsifying properties and its stability during heating. One of most significant aspects of any food emulsion is its stability. Among the methods used to study emulsion stability it may be mentioned visual observation, ultrasound profiling, microscopy, droplet size distribution, small deformation rheometry, measurement of surface concentration to characterize adsorbed protein at the interface, nuclear magnetic resonance, confocal microscopy, diffusing wave spectroscopy, and turbiscan. They have advantages and disadvantages and provide different insights into the destabilization mechanisms. Related to stability, the aspects more deeply investigated were the amount of NaCas used to prepare the emulsion, and specially the oil-to-protein ratio, the mobility of oil droplets and the interactions among emulsion components at the interface. It is known that the amount of protein required to stabilize oil-in-water emulsions depends, not only on the structure of protein at the interface, and the average diameters of the emulsion droplets, but also on the type of oils and the composition of the aqueous phase. Several authors have investigated the effect of a thickening agent or of a surface active molecule. Factors such as pH, temperature, and processing conditions during emulsion preparation are also very relevant to stability. There is a general agreement among authors that the most stable systems are obtained for conditions that produce size reduction of the droplets, an increase in viscosity of the continuous phase and structural changes in emulsions such as gelation. All these conditions decrease the molecular mobility and slow down phase separation.     

Ostwald ripening of protein-stabilized emulsions: effect of transglutaminase crosslinking

Ostwald ripening in n-alkane oil-in-water emulsions stabilized by sodium caseinate at neutral pH has been studied by monitoring time-dependent changes in the number-average droplet diameter and the droplet-size distribution. In qualitative agreement with theory, the destabilization rate has been shown to increase with reduction of the n-alkane chain length and on addition of ethanol to the aqueous phase. Replacement of caseinate by β-lactoglobulin also leads to improved stability, but addition of calcium ions does not. The potential use of transglutaminase-induced crosslinking of adsorbed protein as a way of inhibiting the Ostwald ripening of caseinate-stabilized emulsions has been examined. It is shown that enzymic crosslinking before emulsification can lead to a modest reduction in the coarsening rate at long storage times. Crosslinking of caseinate after emulsification produces enhanced stability at short times, but there is a catastrophic loss of stability at long times due to droplet coalescence.     

Optimization of Oil-in-Water Emulsion Stability: Experimental Design,Multiple Light Scattering,and Acoustic Attenuation Spectroscopy

To find an optimal formulation of oil-in-water (O/W) emulsions (φ_o = 0.05), the effect of emulsifier nature and concentration, agitation speed, emulsifying time, storage temperature and their mutual interactions on the properties and behavior of these dispersions is evaluated by means of an experimental design (Nemrodw software). Long-term emulsion stability is monitored by multiple light scattering (Turbiscan ags) and acoustic attenuation spectroscopy (Ultrasizer). After matching surfactant HLB and oil required HLB, a model giving the Sauter diameter as a function of emulsifier concentration, agitation speed and emulsification time is proposed. The highest stability of C₁₂E₄-stabilized O/W emulsions is observed with 1% emulsifier.     

Performance of a rotating membrane emulsifier for production of coarse droplets

A versatile and high capacity membrane emulsification system which utilises a rotating membrane for the precision manufacture of oil-in-water (o/w) emulsions is investigated. The o/w emulsions produced used a low viscosity paraffin wax as the dispersed phase, Tween 20 or sodium dodecyl sulphate (SDS) as the emulsifier and carbomer as the stabiliser, respectively. The ability to generate coarse monodisperse emulsions was demonstrated with droplets of average diameter 80–570 μm and coefficient of variation ranging from 9.8% to 33.6%. The effects of key process parameters on the droplet size and distribution are discussed, including requirements for future developments of the membrane.     

Influence of sodium dodecyl sulfate on the physicochemical properties of whey protein-stabilized emulsions

The influence of sodium dodecyl sulfate (SDS) on the flocculation of droplets in 20 wt.% soybean oil-in-water emulsions stabilized by whey protein isolate (WPI) was investigated by light scattering, rheology and creaming measurements. The SDS concentrations used were low enough to prevent depletion flocculation by surfactant micelles and extensive protein displacement. In the absence of SDS, emulsions were prone to droplet flocculation near the isoelectric point of the proteins (4<pH<6), but were stable at a higher and lower pH. Flocculation led to an increase in emulsion viscosity, pronounced shear thinning behavior and accelerated creaming. When the surfactant-to-protein molar ratio was increased from 0 to 10, the emulsion instability range shifted to lower pH values due to binding of the negatively charged SDS molecules to the droplets. Our results indicate that the physicochemical properties of protein-stabilized emulsions can be modified by utilizing surfactant–protein interactions.     

Characterization of Astaxanthin Nanoemulsions Produced by Intense Fluid Shear through a Self-Throttling Nanometer Range Annular Orifice Valve-Based High-Pressure Homogenizer

Stable, oil-in-water nanoemulsions containing astaxanthin (AsX) were produced by intense fluid shear forces resulting from pumping a coarse reagent emulsion through a self-throttling annular gap valve at 300 MPa. Compared to crude emulsions prepared by conventional homogenization, a size reduction of over two orders of magnitude was observed for AsX-encapsulated oil droplets following just one pass through the annular valve. In krill oil formulations, the mean hydrodynamic diameter of lipid particles was reduced to 60 nm after only two passes through the valve and reached a minimal size of 24 nm after eight passes. Repeated processing of samples through the valve progressively decreased lipid particle size, with an inflection in the rate of particle size reduction generally observed after 2–4 passes. Krill- and argan oil-based nanoemulsions were produced using an Ultra Shear Technology™ (UST™) approach and characterized in terms of their small particle size, low polydispersity, and stability.     

Drop Size Distribution of O/W Emulsions by Drop Immobilization with Agarose

ABSTRACT

A method for the determination of the drop size distribution of oil-in-water (O/W) emulsions is presented. Water-based coolant emulsions used in rolling mill operations were studied. The emulsions were gelled in agarose so that the oil droplets were immobilized and samples of these gels were measured by confocal laser scanning microscopy (CLSM) and image processing. The influence of the addition of CaCl₂ as an emulsion destabilizer on the size distributions was also studied. The experimental data obtained were compared to those obtained using photon correlation spectroscopy (PCS).     

Fractional crystallization of oil droplets in O/W emulsions dispersed by Synperonic F127

The aim of this works is to study an oil-in-water emulsion stabilized with a triblock copolymer Synperonic F127 which presents a double size distribution of oil droplets. The emulsions were studied experimentally by means of differential scanning calorimetry (DSC) and dynamic light scattering (DLS). The DSC analysis was carried out focusing on the cooling behavior of the emulsion. The cooling thermograms of the oil-in-water emulsion revealed two crystallization peaks with Gaussian profile; the interesting characteristic is that both peaks are separated in temperature. In accordance to previous works for a single oil dispersed within an aqueous phase, the DSC technique must show a single Gaussian peak of crystallization attributable to a size distribution of droplets. In the present case of emulsions stabilized with 1 g/L of Synperonic F127, the aggregation behavior of triblock as a function of temperature allows to produce an emulsion with a double size droplet distribution. Comparison with emulsions stabilized with 2 and 4 wt% of non-ionic Tween 20 are also presented.     

Ripening Phenomena in Emulsions — A Calorimetry Investigation

Ripening phenomena occurring within different kinds of emulsions have been studied. The emulsions concerned are simple water-in-oil (W/O) or oil-in-water (O/W) emulsions, mixed emulsions obtained by the mixture of two simple emulsions, and multiple emulsions water-in-oil-in-water (W/O/W) or oil-in-water-in-oil (O/W/O) emulsions. Composition ripening due to a mass transfer and solid ripening due to the formation of solid particles from the undercooled droplets or due to the formation of solid hydrate around the droplets have been pointed out on using a suitable calorimetric technique. For that purpose a non-diluted emulsion sample is submitted to a cooling and heating cycle during which solidification and melting temperatures and energies of the different phases are analyzed. It has been shown that correlations between these quantities and the properties of the dispersed phase permit one to get information about the ripening phenomena under study. The solution-diffusion model used for mass transfer is in good agreement with the experimental results. From the shell model used for the hydrate formation, it has been possible to deduce the formation energy and the influence of salt upon the temperature of formation.     

Peculiarities of rheological properties and flow of highly concentrated emulsions: The role of concentration and droplet size

Results of a complete study of the rheological properties of highly concentrated emulsions of the w/o type with the content of the dispersed phase up to 96% are reported. The aqueous phase is a supersaturated solution of nitrates, where the water content does not exceed 20%. Dispersed droplets are characterized by a polyhedral shape and a broad size distribution. Highly concentrated emulsions exhibit the properties of rheopectic media. In steady-state regimes of shearing, these emulsions behave as viscoplastic materials with a clearly expressed yield stress. Highly concentrated emulsions are characterized by elasticity due to the compressed state of droplets. Shear storage modulus is constant in a wide range of frequencies that reflect solid-like behavior of such emulsions at small deformations. The storage (dynamic) modulus coincides with the elastic modulus measured in terms of the reversible deformations after the cessation of creep. Normal stresses appear in the shearing. In the low shear rate domain, normal stresses do not depend on shear rate, so that it can be assumed that they have nothing in common with normal stresses arising owing to the Weissenberg effect. These normal stresses can be attributed to Reynolds’ dilatancy (elastic dilatancy). Normal stresses sharply decrease beyond some threshold value of the shear rate and slightly increase only in a high shear rate domain. Observed anomalous flow curves and unusual changes of normal stresses with shear rate are explained by the two-step model of emulsion flow. Direct optical observations show that emulsions move by the mechanism of the rolling of larger droplets over smaller ones without noticeable changes of their shape at low shear rates, while strong distortions of the droplet shape is evident at high shear rates. The transition from one mechanism to the other is attributed to a certain critical value of the capillary number. The concentration dependence of the elastic modulus (as well as the yield stress) can be described by the Princen-Kiss model, but this model fails to predict the droplet size dependence of the elastic modulus. Numerous experiments demonstrated that the modulus and yield stress are proportional to the squared reciprocal size, while the Princen-Kiss model predicts their linear dependence on the reciprocal size. A new model based on dimensional arguments is proposed. This model correctly describes the influence of the main structural parameters on the rheological properties of highly concentrated emulsions. The boundaries of the domain of highly concentrated emulsions are estimated on the basis of the measurement of their elasticity and yield stress.     

The heat stability of milk protein-stabilized oil-in-water emulsions: A review

The knowledge on the factors affecting the heat-induced physicochemical changes of milk proteins and milk protein stabilized oil-in-water emulsions has been advanced for the last decade. Most of the studies have emphasized on the understanding of how milk-protein-stabilized droplets and the non-adsorbed proteins determine the physicochemical and rheological properties of protein-concentrated dairy colloids. The physical stability of concentrated protein-stabilized emulsions (i.e., against creaming or phase separation/gelation after heat treatment) can be modulated by carefully controlling the colloidal properties of the protein-stabilized droplets and the non-adsorbed proteins in the aqueous phase. This article focusses on the review of the physical stability of concentrated milk protein-stabilized oil-in-water emulsions as influenced by physicochemical factors, interparticle interactions (i.e., protein–protein, and droplet–droplet interactions) and processing conditions. Emphasis has been given to the recent advances in the formation, structure and physical stability of oil-in-water emulsions prepared with all types of milk proteins, reviewing in particular the impact of pre- and post-homogenization heat treatments. In addition, the importance of common components found in the continuous phase of heat-treated nutritional emulsions that can promote aggregation (polymers, sugars, minerals) will be highlighted. Finally, the routes of manipulating the steric stabilization of these emulsions to control heat-induced aggregation—through protein–surfactant, protein–protein, protein–polysaccharide interactions and through the incorporation of protein based colloidal particles—are reviewed.     

High-volume production of single and compound emulsions in a microfluidic parallelization arrangement coupled with coaxial annular world-to-chip interfaces

This study describes a microfluidic platform with coaxial annular world-to-chip interfaces for high-throughput production of single and compound emulsion droplets, having controlled sizes and internal compositions. The production module consists of two distinct elements: a planar square chip on which many copies of a microfluidic droplet generator (MFDG) are arranged circularly, and a cubic supporting module with coaxial annular channels for supplying fluids evenly to the inlets of the mounted chip, assembled from blocks with cylinders and holes. Three-dimensional flow was simulated to evaluate the distribution of flow velocity in the coaxial multiple annular channels. By coupling a 1.5 cm × 1.5 cm microfluidic chip with parallelized 144 MFDGs and a supporting module with two annular channels, for example, we could produce simple oil-in-water (O/W) emulsion droplets having a mean diameter of 90.7 μm and a coefficient of variation (CV) of 2.2% at a throughput of 180.0 mL h(-1). Furthermore, we successfully demonstrated high-throughput production of Janus droplets, double emulsions and triple emulsions, by coupling 1.5 cm × 1.5 cm - 4.5 cm × 4.5 cm microfluidic chips with parallelized 32-128 MFDGs of various geometries and supporting modules with 3-4 annular channels.